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DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER OPERATION & MAINTENANCE MANUAL 950106-01403NAMH – PDF DOWNLOAD
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DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER OPERATION & MAINTENANCE MANUAL 950106-01403NAMH – PDF DOWNLOAD
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Description
DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER OPERATION & MAINTENANCE MANUAL 950106-01403NAMH – PDF DOWNLOAD
DESCRIPTION:
DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER OPERATION & MAINTENANCE MANUAL 950106-01403NAMH – PDF DOWNLOAD
Foreword
This Operation & Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT
Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment.
Any modification made without written authorization or approval from DOOSAN can create a safety hazard. Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.
Intended Use
The machine is intended to be used under normal conditions for applications described in this manual. If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use.Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual. Contact your DOOSAN distributor for further information.
Engine and Emission Control Syste Maintenance
Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating. This includes proper inspection and maintenance of the machine’s emission control system. This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and/or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance. The required maintenance procedures are outlined in this Operation & Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system.
TABLE OF CONTENTS:
DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER OPERATION & MAINTENANCE MANUAL 950106-01403NAMH – PDF DOWNLOAD
Foreword.................................................................................................................................................... 9 Intended Use............................................................................................................................................ 9 Engine and Emission Control System Maintenance.......................................................................................................... 9 Machine Capacity........................................................................................................................................ 10 Product Identification Number (PIN)..................................................................................................................... 10 Component Model and Serial Numbers.................................................................................................................. 11 Tilting Riser and Elevating Cabin Serial Numbers.................................................................................................... 11 Safety Messages......................................................................................................................................... 12 Signal Words........................................................................................................................................ 12 Other Signal Words.................................................................................................................................. 13 AEM Safety Manual (North America Only).................................................................................................................. 13 Federal Emission Control Systems........................................................................................................................ 14 Limited Warranty for Non-road Engines (CI).......................................................................................................... 14 Owner's Warranty Rights and Obligations............................................................................................................. 14 Fuel Metering System............................................................................................................................ 14 Air Induction System............................................................................................................................ 14 Catalyst or Thermal Reactor System.............................................................................................................. 14 Exhaust Gas Recirculation (EGR) System.......................................................................................................... 14 Aftertreatment System........................................................................................................................... 14 Miscellaneous Items Used In The Emission Control Systems........................................................................................ 14 Manufacturer's Warranty Coverage.................................................................................................................... 15 Owner's Warranty Responsibilities................................................................................................................... 15 Safety...................................................................................................................................................... 17 Safety Decals........................................................................................................................................... 18 Safety Decals With Text............................................................................................................................. 18 Safety Decals Without Text (No-Text)................................................................................................................ 19 Information and Location for Safety Decals.......................................................................................................... 20 Tilting Riser................................................................................................................................... 20 Information and Location for Safety Decals (Continued).............................................................................................. 21 Tilting Riser (Continued)....................................................................................................................... 21 Information and Location for Safety Decals (Continued).............................................................................................. 22 Elevating Cabin................................................................................................................................. 22 Information and Location for Safety Decals (Continued).............................................................................................. 23 Elevating Cabin (Continued)..................................................................................................................... 23 1. Operation & Maintenance Manual, Seat Belt, Electrocution and Explosion, When Leaving the Material Handler (950205-01466C, 950205-01684A)..... 24 2. Operating Control Pattern (Optional) (950205-01404C)......................................................................................... 25 3. Work Equipment Interference (950205-01680)................................................................................................... 25 4. Front Slide Window (950205-01460B)........................................................................................................... 26 5. Visibility (950205-00862A, 950205-00863A).................................................................................................... 26 6. Warning Tag - Used for Inspection and Maintenance (950205-01451, 950205-01760)............................................................... 27 7. Stay Away (950205-01455B, 950205-01761)...................................................................................................... 27 8. Hot Pressurized Fluid (950205-01453, 950205-01675A).......................................................................................... 28 9. High-pressure (950205-01454A, 950205-01762).................................................................................................. 28 10. Rotating Parts (950205-01467B, 950205-01674 + 950205-01676)................................................................................. 29 11. Fall Hazard (950205-01763, 950205-01872).................................................................................................... 29 12. Batteries (950205-01448, 950205-01677)...................................................................................................... 30 13. Hot Pressurized Oil (950205-01450B, 950205-01675A).......................................................................................... 31 14. Hot Surface (950205-01748).................................................................................................................. 31 15. Tool Box/Battery Box Doors. (950205-01468A, 950205-01738)................................................................................... 32 16. Thrown or Flying Objects/Track Adjuster (950205-01463A)..................................................................................... 33 17. Crush Hazard/Front Work Equipment (950205-01464A)........................................................................................... 33 18. Rotating Fan (950205-01482, 950205-01676)................................................................................................... 34 19. Pinch Point (7233513) (Elevating Cabin Only)................................................................................................ 34 20. Crush Hazard (7233514) (Elevating Cabin Only)............................................................................................... 35 21. Unsecured Cabin (7233518) (Tilt Riser Only)................................................................................................. 35 22. Falling Hazard (7233519) (Tilt Riser Only).................................................................................................. 36 23. Crush Hazard (7233520) (Tilt Riser Only).................................................................................................... 36 Information and Location of Additional Decals....................................................................................................... 37 Tilting Riser................................................................................................................................... 37 Information and Location of Additional Decals (Continued)........................................................................................... 38 Tilting Riser (Continued)....................................................................................................................... 38 Information and Location of Additional Decals (Continued)........................................................................................... 39 Elevating Cabin................................................................................................................................. 39 Information and Location of Additional Decals (Continued)........................................................................................... 40 Elevating Cabin (Continued)..................................................................................................................... 40 1. Sound Pressure Level (Optional) (190-01059).................................................................................................. 41 2. Ultra Low Sulfur Diesel Fuel Only (950205-01402)............................................................................................. 41 3. Lifting and Tie Down Point (K1042074A)....................................................................................................... 41 4. Emergency Cabin Lowering (7238715) (Elevating Cabin Only).................................................................................... 42 5. Emergency Cabin Lowering (7238716) (Elevating Cabin Only).................................................................................... 42 6. Emergency Cabin Lowering (7238717) (Elevating Cabin Only).................................................................................... 42 7. Controls - Grapple Operation................................................................................................................. 43 General................................................................................................................................................. 44 Safe Operation is Operator's Responsibility......................................................................................................... 44 Know Your Machine................................................................................................................................... 44 Proper Work Tools and Attachments................................................................................................................... 45 Pressurized Fluids.................................................................................................................................. 45 Flying or Falling Objects........................................................................................................................... 46 Personal Protective Equipment (PPE)................................................................................................................. 47 Correction of Machine Problems...................................................................................................................... 47 Crushing and Cutting................................................................................................................................ 47 Hot Coolant and Oils - Burn Prevention.............................................................................................................. 48 Fire and Explosion Prevention....................................................................................................................... 49 Maintenance..................................................................................................................................... 49 Operation....................................................................................................................................... 49 Electrical...................................................................................................................................... 50 Hydraulic System................................................................................................................................ 50 Fueling......................................................................................................................................... 51 Never Use Ether Starting Aids................................................................................................................... 51 Welding and Grinding............................................................................................................................ 51 If a Fire Occurs................................................................................................................................ 52 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)......................................................................................... 52 Electrical System and Electrical Shock.............................................................................................................. 53 Protecting Cabin from Flying or Falling Objects (Optional)...................................................................................... 54 Emergency Exit from Operator's Station.......................................................................................................... 55 Tilting Riser Egress Ladder..................................................................................................................... 55 Lowering Elevating Cabin........................................................................................................................ 56 Transportation.......................................................................................................................................... 57 Obey State and Local Over-the-Road Regulations...................................................................................................... 57 Loading and Unloading............................................................................................................................... 57 Transporting Machine................................................................................................................................ 58 Operation............................................................................................................................................... 59 Before Engine Starting.............................................................................................................................. 59 Machine Condition............................................................................................................................... 59 Work Site........................................................................................................................................... 60 Mounting/Dismounting................................................................................................................................ 61 Elevating Cabin (If Equipped)................................................................................................................... 61 Tilting Riser (If Equipped)..................................................................................................................... 62 Cleaning............................................................................................................................................ 63 Operator Station.................................................................................................................................... 63 Seat Belt........................................................................................................................................... 64 Visibility Information.............................................................................................................................. 65 Work Site Rules................................................................................................................................. 65 Boost Starting or Charging Engine Batteries......................................................................................................... 66 Starting Engine..................................................................................................................................... 67 Swinging or Traveling............................................................................................................................... 68 Lifting............................................................................................................................................. 70 Towing.............................................................................................................................................. 71 Attachment.......................................................................................................................................... 72 Equipment Lowering with Engine Stopped.............................................................................................................. 72 Lowering Elevating Cabin with Engine Stopped........................................................................................................ 73 Engine Stop......................................................................................................................................... 73 Parking Machine..................................................................................................................................... 74 Preservation/Storing Machine........................................................................................................................ 75 Check After Long-term Parking................................................................................................................... 76 Maintenance............................................................................................................................................. 77 Warning Tag......................................................................................................................................... 80 Cleaning............................................................................................................................................ 81 Proper Tools and Clothing........................................................................................................................... 81 Disassembling Precautions........................................................................................................................... 81 Use of Lighting..................................................................................................................................... 82 Fire and Explosion Prevention....................................................................................................................... 82 Burn Prevention..................................................................................................................................... 83 Rubber That Contains Fluorides...................................................................................................................... 84 Rubber and Plastics................................................................................................................................. 85 Waste Hazardous to the Environment.............................................................................................................. 85 Check List After Fire........................................................................................................................... 85 Welding Repairs..................................................................................................................................... 86 Preparation for Electrical Welding On Body Structure............................................................................................ 87 Warning for Counterweight and Front Attachment Removal.............................................................................................. 87 Lock Inspection Covers.............................................................................................................................. 88 Working on Machine.................................................................................................................................. 88 Accumulator......................................................................................................................................... 89 Compressed Air...................................................................................................................................... 89 Track Tension Adjustments........................................................................................................................... 90 Supports and Blocking for Work Equipment............................................................................................................ 90 High-pressure Lines, Tubes and Hoses................................................................................................................ 91 Battery............................................................................................................................................. 92 Battery Hazard Prevention....................................................................................................................... 92 Environment and Circumstances........................................................................................................................... 94 Work Site Areas Requiring Extra Caution............................................................................................................. 94 Drop-off or Edge................................................................................................................................ 94 Poor Visibility................................................................................................................................. 94 Loose or Soft Ground............................................................................................................................ 95 High-voltage Cables................................................................................................................................. 95 Working in Water.................................................................................................................................... 96 Working in Contaminated Environment................................................................................................................. 96 Operation in Extreme Conditions..................................................................................................................... 97 Operation In Extreme Cold....................................................................................................................... 97 Operation in Extreme Heat....................................................................................................................... 98 Operation In Dusty and Sandy Areas.............................................................................................................. 99 Operation in Rainy or Humid Conditions.......................................................................................................... 99 Operation in Saltwater Areas....................................................................................................................100 Operation at High Altitudes.....................................................................................................................100 Operation During Electrical Storms..............................................................................................................100 Exhaust Ventilation.................................................................................................................................101 Ventilation for Enclosed Area...................................................................................................................101 Asbestos Information................................................................................................................................101 Silica Dust Information.............................................................................................................................102 Disposal of Hazardous Materials.....................................................................................................................102 Sound...............................................................................................................................................103 Vibration...........................................................................................................................................103 Operating Controls..........................................................................................................................................105 Component Locations.....................................................................................................................................106 Tilting Riser.......................................................................................................................................108 Elevating Cabin.....................................................................................................................................109 Operator's Area.........................................................................................................................................110 Operational Controls and Panels.........................................................................................................................112 1. Starter Switch...................................................................................................................................114 2. Heater and Air Conditioner Control Panel.........................................................................................................114 3. Power Socket for 12 Volt.........................................................................................................................115 4. Cigarette Lighter................................................................................................................................115 5. Engine Emergency Stop Switch.....................................................................................................................115 6. Engine Speed Control Dial........................................................................................................................116 7. Travel Speed Selector Switch.....................................................................................................................116 8. Light Switch.....................................................................................................................................116 9. Elevating Cabin Switch (Optional)................................................................................................................117 10. Cabin Work Light Switch (Optional)..............................................................................................................117 11. Audio Control Panel.............................................................................................................................117 12. Wiper Control Panel.............................................................................................................................119 13. Generator Switch (If Equipped)..................................................................................................................120 14. Air Compressor Switch (Optional)................................................................................................................120 15. Warning Light Switch (Optional).................................................................................................................120 16. Lower Wiper Switch (Optional)...................................................................................................................121 17. Travel/Swing Alarm Switch (Optional)............................................................................................................121 18. Fuel Heater Switch (Optional)...................................................................................................................121 19. Overload Warning Switch (Not Applicable)........................................................................................................122 20. Power Socket for 12 Volt (Optional).............................................................................................................122 21. Horn Button (Left-hand Work Lever)..............................................................................................................122 22. Booster Button / Magnet Control (If Equipped)...................................................................................................123 23. Rotating Switch.................................................................................................................................123 24. Shear Switch (Not Applicable)...................................................................................................................123 25. Display Monitor.................................................................................................................................124 26. Photo Sensor....................................................................................................................................124 27. Safety Lever....................................................................................................................................124 28. Auxiliary Mode Switch...........................................................................................................................125 29. Hour Meter......................................................................................................................................125 30. Diesel Particulate Filter (DPF) Switch..........................................................................................................126 31. One Touch Deceleration Button...................................................................................................................126 32. Intelligent Floating Boom Temporary Reset Button (Not Applicable)...............................................................................127 33. Jog Switch Control Panel........................................................................................................................127 34. Jack Assembly...................................................................................................................................129 35. Micro Phone (Optional)..........................................................................................................................129 36. Elevating Cabin Lowering Valve (Elevating Cabin Only)...........................................................................................130 Tilting Riser...........................................................................................................................................131 Hydraulic Pump for Tilting Cylinder.................................................................................................................131 Raising Riser/Cabin to Operating Position...........................................................................................................132 Lowering Riser/Cabin to Transport Position..........................................................................................................136 Elevating Cabin.........................................................................................................................................140 Raising.............................................................................................................................................140 Lowering............................................................................................................................................140 Display Monitor.........................................................................................................................................141 Functional Check....................................................................................................................................141 Password Activated..................................................................................................................................142 1. Fuel Gauge.......................................................................................................................................142 2. Engine Coolant Temperature Gauge.................................................................................................................142 3. Hydraulic Oil Temperature Gauge..................................................................................................................143 4. Multifunction Gauge and Graphic Information Area.................................................................................................143 5. ECO Gauge........................................................................................................................................145 6. Digital Clock....................................................................................................................................145 7. Display Warning Symbols..........................................................................................................................146 8. Warning Light....................................................................................................................................151 9. Function Buttons.................................................................................................................................152 1. Menu 2 Selector Button.......................................................................................................................152 2. Power Mode Selector Button...................................................................................................................152 3. Auto Idle Selector Button....................................................................................................................152 4. Work Mode Selector Button....................................................................................................................153 5. Selection Bar Move () Button.................................................................................................................153 6. Selection Bar Move () Button.................................................................................................................153 7. Menu Selector Button.........................................................................................................................153 8. Camera Mode Selector/Escape (ESC) Button.....................................................................................................153 9. Entertainment Button.........................................................................................................................153 10. Menu 1 Selector Button......................................................................................................................153 10. Mode Selector Buttons...........................................................................................................................154 11. Selector Function Display.......................................................................................................................155 12. Jog Switch......................................................................................................................................155 13. Camera Mode Selector/ESC Button.................................................................................................................155 14. Multimedia Selector Button......................................................................................................................156 Warning Pop-up Window...............................................................................................................................156 Warning Pop-up Windows List.....................................................................................................................158 User Menu...............................................................................................................................................159 User Menu - Access and Escape Methods...............................................................................................................159 Access Method...................................................................................................................................159 Escape Method...................................................................................................................................159 User Menu.......................................................................................................................................159 Switch Operation Indication.........................................................................................................................187 Heater and Air Conditioner Control Panel................................................................................................................190 Location of Controls and Vents......................................................................................................................190 Control Panel.......................................................................................................................................191 1. Automatic Temperature Control Button.........................................................................................................191 2. Off Button...................................................................................................................................192 3. Temperature Control Button...................................................................................................................192 4. Temperature Unit Selector Button.............................................................................................................192 5. Mode Selector Button.........................................................................................................................192 6. Air Inlet Selector Button....................................................................................................................194 7. Fan Speed Selector Buttons...................................................................................................................194 8. Air Conditioner Button.......................................................................................................................194 9. Defroster Button.............................................................................................................................195 10. LCD Display.................................................................................................................................195 Memory Function.....................................................................................................................................195 Additional Operating Instructions...................................................................................................................195 Stereo..................................................................................................................................................196 Stereo..............................................................................................................................................196 CD Player (Optional)................................................................................................................................196 Miscellaneous Electrical Devices........................................................................................................................197 Cabin Light.........................................................................................................................................197 Pilot Cutoff Switch.................................................................................................................................197 Circuit Breaker.....................................................................................................................................197 Fusible Link........................................................................................................................................198 Fuse Boxes..........................................................................................................................................198 Seat Adjustment.........................................................................................................................................199 1. Forward/Backward Adjustment......................................................................................................................199 2. Adjusting Height of Seat and Depth of Cushion....................................................................................................199 Forward Tilt....................................................................................................................................199 Cushion Slide...................................................................................................................................199 Seat Height.....................................................................................................................................199 3. Reclining Position Adjustment....................................................................................................................200 4. Lumbar Support Adjustment........................................................................................................................200 5. Headrest.........................................................................................................................................200 6. Seat Belt........................................................................................................................................200 Seat Belt Locking and Unlocking.................................................................................................................201 7. Storage Compartment..............................................................................................................................201 8. Left and Right Control Stand Adjustment..........................................................................................................201 9. Left and Right Control Stand Height Adjustment...................................................................................................202 10. Adjusting Height/Angle of Armrest...............................................................................................................202 11. Heating Operator's Seat.........................................................................................................................202 Ceiling Cover...........................................................................................................................................203 Opening Ceiling Cover...............................................................................................................................203 Closing Ceiling Cover...............................................................................................................................203 Front Windows...........................................................................................................................................204 Front Upper Window..................................................................................................................................204 Opening Window..................................................................................................................................204 Closing Window..................................................................................................................................205 Front Bottom Window.................................................................................................................................205 Closing Window..................................................................................................................................206 Door Side Latch.........................................................................................................................................206 Cabin Riser Access Door.................................................................................................................................207 Cabin Storage Compartments..............................................................................................................................207 Sunglass Case...........................................................................................................................................208 Sun Visor...............................................................................................................................................208 Front Window Visor..................................................................................................................................208 Ceiling Window Visor................................................................................................................................209 Hanger..................................................................................................................................................209 Cup Holder..............................................................................................................................................210 Emergency Exit Glass Breaking Tool......................................................................................................................210 Miscellaneous Access Covers and Doors...................................................................................................................211 Side Door...........................................................................................................................................211 Battery Box Door....................................................................................................................................211 Opening.........................................................................................................................................211 Closing.........................................................................................................................................211 Engine Cover........................................................................................................................................211 Air Gun and Compressor (Optional).......................................................................................................................212 Air Gun (Optional)..................................................................................................................................212 How to Use Air Compressor...........................................................................................................................212 How to Connect Air Gun..............................................................................................................................214 Operation...................................................................................................................................................215 To Operate a New Material Handler.......................................................................................................................215 Lubrication and Filters.............................................................................................................................216 Starting and Stopping Engine............................................................................................................................216 Inspection Before Starting Engine...................................................................................................................216 Walk Around Checks..............................................................................................................................216 Checks Before Starting Engine...................................................................................................................217 Operational Checks Before Starting Engine...........................................................................................................218 Engine Start........................................................................................................................................219 Cold Weather Starting...............................................................................................................................221 Engine Coolant Heater (Optional)....................................................................................................................223 Starting Engine With a Booster Cable................................................................................................................225 Connecting Booster Batteries....................................................................................................................225 Disconnecting Booster Batteries.................................................................................................................226 Hydraulic System Warm-up............................................................................................................................226 Hydraulic System Warm-up – Cold Weather.............................................................................................................227 Stopping Engine.....................................................................................................................................229 Checks and Maintenance After Stopping Engine........................................................................................................230 Safety Lever............................................................................................................................................230 Travel..................................................................................................................................................231 Automatic Travel Speed Control......................................................................................................................231 Travel Control Lever Operation......................................................................................................................232 General Travel Instructions.........................................................................................................................233 Straight Travel Pedal (Optional)....................................................................................................................235 Operating.......................................................................................................................................236 Locking Pedal...................................................................................................................................236 Operating Instructions..................................................................................................................................237 Engine Speed Control................................................................................................................................237 Engine Exhaust Emission Control System..............................................................................................................237 Regeneration of Diesel Particulate Filter (DPF).................................................................................................238 Diesel Particulate Filter (DPF) Regeneration Light and Switch...................................................................................238 Passive Regeneration............................................................................................................................241 Active Regeneration.............................................................................................................................241 Manual (Forced) Regeneration....................................................................................................................242 DPF Cleaning (Removing Ash in DPF)..............................................................................................................244 Removal and Installation of the DPF Assembly....................................................................................................245 Mode Selection......................................................................................................................................246 Power Mode......................................................................................................................................246 Work Mode.......................................................................................................................................247 Auto Idle Mode..................................................................................................................................247 Boost Mode......................................................................................................................................248 Work Levers (Joysticks) (ISO Pattern)...............................................................................................................249 Left-hand Work Lever (Joystick) (Figure 58 and Figure 59).......................................................................................249 Right-hand Work Lever (Joystick) (Figure 58 and Figure 61)......................................................................................249 Change Machine Control Pattern By Selector Valve (If Equipped)......................................................................................250 Work Levers (Joysticks) (BHL Pattern)...............................................................................................................251 Left-hand Work Lever (Joystick) (Figure 62 and Figure 64).......................................................................................251 Right-hand Work Lever (Joystick) (Figure 62 and Figure 65)......................................................................................251 Operating Precautions...................................................................................................................................252 Working in Water....................................................................................................................................257 Parking Material Handler................................................................................................................................258 Towing Procedure........................................................................................................................................259 Attachments.............................................................................................................................................260 Rotating Operation..................................................................................................................................260 Lifting Objects.........................................................................................................................................261 Lifting Unknown Weight..............................................................................................................................262 Lifting Known Weight................................................................................................................................262 Pick and Carry......................................................................................................................................262 Operation Under Abnormal Conditions.....................................................................................................................263 Operation in Extreme Cold...........................................................................................................................263 Operation in Extreme Heat...........................................................................................................................264 Operation in Dusty and Sandy Areas..................................................................................................................265 Operation in Rainy or Humid Conditions..............................................................................................................266 Operation in Saltwater Areas........................................................................................................................266 Operation During Electrical Storms..................................................................................................................266 Operation at High Altitudes.........................................................................................................................267 Equipment Lowering with Engine Stopped..............................................................................................................267 Machine with a Boom Lowering Control Valve......................................................................................................268 Long Term Storage.......................................................................................................................................269 Before Storage......................................................................................................................................269 During Storage......................................................................................................................................270 After Storage.......................................................................................................................................270 Inspection, Maintenance and Adjustment......................................................................................................................271 Maintenance Information.................................................................................................................................271 Operational Hour Meter Reading......................................................................................................................271 DOOSAN Genuine Replacement Parts....................................................................................................................271 DOOSAN Genuine Lubricants...........................................................................................................................271 Windshield Washer Fluid.............................................................................................................................271 Fresh and Clean Lubricants..........................................................................................................................271 Check Drained Oil and Used Filter...................................................................................................................271 Fuel Strainer.......................................................................................................................................271 Welding Instructions................................................................................................................................272 Do Not Drop Things Inside Machine...................................................................................................................272 Dusty Work Site.....................................................................................................................................272 Avoid Mixing Lubricants.............................................................................................................................272 Locking Inspection Covers...........................................................................................................................272 Hydraulic System - Air Bleeding.....................................................................................................................273 Hydraulic Hose Installation.........................................................................................................................273 Checks After Inspection and Maintenance Works.......................................................................................................273 Safety Precautions..................................................................................................................................274 Machine Setup Position for Maintenance..................................................................................................................275 Maintenance Handling Access.............................................................................................................................277 Entering/Leaving/Climbing On Machine................................................................................................................277 Elevating Cabin (If Equipped)...................................................................................................................277 Titling Riser (If Equipped).....................................................................................................................278 Handling Oil, Fuel, Coolant.............................................................................................................................279 Oil.................................................................................................................................................279 Fuel................................................................................................................................................279 Engine Oil..........................................................................................................................................281 Grease..............................................................................................................................................282 Coolant and Water for Dilution......................................................................................................................282 Filters.............................................................................................................................................283 Electrical System Maintenance...........................................................................................................................284 Recommend Fuel, Coolant, and Lubricant..................................................................................................................285 Lubrication.........................................................................................................................................285 Symbols for "Lubrication and Service Chart".........................................................................................................286 Lubrication and Service Chart...................................................................................................................287 Lubrication and Service Chart (Continued).......................................................................................................288 Fluid Capacities........................................................................................................................................290 Table of Recommended Lubricants.........................................................................................................................291 Maintenance Intervals...................................................................................................................................293 10 Hour / Daily Service.................................................................................................................................296 Grease Boom, Arm and Front Attachment Pins (for first 100 hours)....................................................................................296 Grease Elevating Cabin Linkage Pins (If equipped) (for first 100 hours).............................................................................296 Check Engine Oil Level..............................................................................................................................296 Check Level of Hydraulic Oil Tank...................................................................................................................297 Check for Leaks in Hydraulic System.................................................................................................................298 Check Fuel Level....................................................................................................................................299 Check for Leaks in Fuel System......................................................................................................................300 Check Fuel Prefilter and Drain Water As Required....................................................................................................300 Check Oil Level of Swing Reduction Device...........................................................................................................301 Clean Dust Net in Front of Oil Cooler and Radiator..................................................................................................302 Oil Cooler......................................................................................................................................302 Radiator........................................................................................................................................302 Check Cooling System and Refill As Required.........................................................................................................303 Check Level of Window Washer Liquid.................................................................................................................303 Inspect Cooling Fan Blade...........................................................................................................................304 Check Air Intake System and Emission Control System Components......................................................................................305 Inspect Seat Belt for Proper Operation..............................................................................................................305 Inspect Rear View Camera for Proper Operation (If Equipped).........................................................................................305 Inspect Mirrors for Damage and Adjust and Clean as Required.........................................................................................306 Inspect Structure for Cracks and Faulty Welds.......................................................................................................306 Check Operation of All Switches and Travel Alarm (If Equipped)......................................................................................306 Check the Operation of Pilot Cutoff Switch..........................................................................................................306 Inspection and Maintenance of the Pilot Cutoff Switch...........................................................................................306 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor......................................................307 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds.....308 Check Operation of All Controls and Linkages........................................................................................................308 50 Hour / Weekly Service................................................................................................................................309 Perform All Daily Service Checks....................................................................................................................309 Grease Boom and Attachment Joint Pin................................................................................................................309 Grease Elevating Cabin Linkage Pins.................................................................................................................311 Grease Swing Bearing................................................................................................................................312 Drain Water and Sediment from Fuel Tank.............................................................................................................313 Check Air Compressor and Drain Water as Required....................................................................................................313 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)...................................................................314 Change Engine Oil and Filter (After First 50 Hours).................................................................................................314 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)....................................314 250 Hour / Monthly Service..............................................................................................................................315 Perform All Daily and 50 Hour Service Checks........................................................................................................315 Hydraulic Pump for Tilt Cylinder....................................................................................................................315 Check Engine Fan and Alternator Belts Tension.......................................................................................................316 Check Engine Fan and Alternator Belts Wear..........................................................................................................317 Check Oil Bath Precleaner (Optional)................................................................................................................318 Clean Oil Bath Precleaner (Optional)................................................................................................................318 Replace Hydraulic Oil Return Filter (After First 250 Hours).........................................................................................321 Change Pilot Filter (After First 250 Hours).........................................................................................................321 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear............................................................................321 Check Fluid Levels in Batteries and Battery Charge Levels...........................................................................................321 Inspect for Any Loose or Missing Nuts and Bolts.....................................................................................................321 Inspect Fuel System Hose Clamps.....................................................................................................................321 500 Hour / 3 Month Service..............................................................................................................................322 Perform All Daily, 50 and 250 Hour Service Checks...................................................................................................322 Grease Swing Gear and Pinion........................................................................................................................322 Change Engine Oil and Filter........................................................................................................................323 Clean Air-conditioning Outer Filter.................................................................................................................324 Check and Clean Air-conditioning Inner Filter.......................................................................................................325 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores............................................................326 Clean Outer Filter of Air Cleaner...................................................................................................................327 Change of Fuel Prefilter............................................................................................................................329 Change Fuel Filter..................................................................................................................................330 Fuel System Priming.............................................................................................................................330 Clean Air Compressor Filter (Optional)..............................................................................................................331 Check Oil Level in Travel Reduction Device (One on Each Side of Unit)...............................................................................332 Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)............................................................332 Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)..........................................................................332 1,000 Hour / 6 Month Service............................................................................................................................333 Perform All Daily, 50, 250 and 500 Hour Service Checks..............................................................................................333 Grease Swing Reduction Device.......................................................................................................................333 Change Hydraulic Oil Tank Breather Filter...........................................................................................................333 Change Pilot Filter.................................................................................................................................335 Change Oil in Travel Reduction Device (One on Each Side of Unit)....................................................................................336 Change Swing Reduction Device Oil...................................................................................................................337 Change Air-conditioning Outer Filter................................................................................................................338 Change Air-conditioning Inner Filter................................................................................................................338 Check Air Conditioner Refrigerant...................................................................................................................339 Change Fuel Cap Filter..............................................................................................................................340 Check and Adjust Engine**...........................................................................................................................341 2,000 Hour / Yearly Service.............................................................................................................................342 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks.......................................................................................342 Replace Outer and Inner Air Cleaner Filters.........................................................................................................342 Change Radiator Coolant.............................................................................................................................344 Change Air Compressor Filter (Optional).............................................................................................................345 Replace Breather Oil Separator Filter...............................................................................................................346 Hydraulic Oil Exchange and Suction Strainer Cleaning................................................................................................347 Check Alternator and Starter**......................................................................................................................349 Check All Rubber Antivibration Shock Mounts.........................................................................................................349 Perform and Record Results of Cycle Time Tests......................................................................................................349 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.....................................................................349 Check, Adjust Valve Clearance**.....................................................................................................................349 Check Head Bolt Torques.............................................................................................................................349 4,000 Hour / Biennial Service...........................................................................................................................350 Major Parts - Periodic Replacement..................................................................................................................350 4,500 Hour / Biennial Service...........................................................................................................................351 Clean Diesel Particulate Filter (DPF)...............................................................................................................351 12,000 Hour / 6 Year Service............................................................................................................................352 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN)).........................................................................352 Air-conditioning System.................................................................................................................................353 Check Control Panel.................................................................................................................................353 Check Air Conditioner Hoses.........................................................................................................................353 Check Condenser.....................................................................................................................................353 Check Magnetic Clutch...............................................................................................................................353 Check Belt Tension..................................................................................................................................353 Bolt and Nut Inspection.................................................................................................................................354 Electrical System.......................................................................................................................................363 Battery.............................................................................................................................................363 Batteries in Cold Weather.......................................................................................................................363 Inspection of Battery Electrolyte Level.........................................................................................................364 Check Charging State............................................................................................................................364 Check Battery Terminals.........................................................................................................................364 Battery Replacement.............................................................................................................................364 Fuses...............................................................................................................................................365 Fuse Boxes......................................................................................................................................365 Tilting Riser In-line Fuse......................................................................................................................366 Fuse Identification.............................................................................................................................367 Engine Cooling System...................................................................................................................................368 General.............................................................................................................................................368 Types of Antifreeze.............................................................................................................................369 Antifreeze Concentration Tables.....................................................................................................................370 Fuel Transfer Pump (Optional)...........................................................................................................................371 Handling of Accumulator.................................................................................................................................374 Track Tension...........................................................................................................................................375 Venting and Priming Hydraulic System....................................................................................................................377 Main System Pump....................................................................................................................................377 Hydraulic Cylinders.................................................................................................................................377 Swing Motor.........................................................................................................................................378 Travel Motor........................................................................................................................................378 General Venting.....................................................................................................................................378 Maintenance in Special Conditions.......................................................................................................................379 Transportation..............................................................................................................................................381 Loading and Unloading...................................................................................................................................381 Warning for Counterweight and Front Attachment Removal..............................................................................................381 Counterweight.......................................................................................................................................382 Removal.........................................................................................................................................382 Installation....................................................................................................................................384 Loading and Unloading Machine.......................................................................................................................385 Lifting Machine.........................................................................................................................................389 Troubleshooting.............................................................................................................................................391 Electrical System.......................................................................................................................................391 Engine..................................................................................................................................................392 Variable Geometry turbocharger (VGT)....................................................................................................................396 Lubrication System......................................................................................................................................397 Hydraulic System........................................................................................................................................398 Air Compressor (Optional)...............................................................................................................................399 Swing System............................................................................................................................................400 Travel System...........................................................................................................................................400 Hydraulic Fan Drive System..............................................................................................................................401 Elevating Cabin.........................................................................................................................................401 Tilting Riser...........................................................................................................................................402 Specification...............................................................................................................................................403 Standard Specification..................................................................................................................................403 Overall Dimensions......................................................................................................................................404 Tilting Riser With One - Piece Boom.................................................................................................................404 Elevating Cabin With One - Piece Boom...............................................................................................................405 Disassembled Parts, Dimension and Weight................................................................................................................406 Components..........................................................................................................................................406 Boom............................................................................................................................................406 Arm.............................................................................................................................................407 Counterweight...................................................................................................................................407 Counterweight (Cont'd)..........................................................................................................................408 Working Range...........................................................................................................................................409 One - Piece Boom....................................................................................................................................409 Material Handler Rated Lift Capacity Tables.........................................................................................................410 Rated Lift Capacity Table (Metric)..............................................................................................................412 Rated Lift Capacity Table (Standard)............................................................................................................413 Index.......................................................................................................................................................415
DOOSAN DX300MH 3 EXCAVATOR MATRIAL HANDLER OPERATION & MAINTENANCE MANUAL 950106-01403NAMH – PDF DOWNLOAD:
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